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Carpentry and Joinery 1 This Page Intentionally Left Blank Carpentry and Joinery Third Edition 1 Brian Porter LCG, FIOC Formerly of Leeds College of Building First published in Great Britain 1984 Second edition 1991 by Edward Arnold Third edition 2001 by Butterworth Heinemann © 2001 Brian Porter All rights reserved. No part of this publication may be reproduced or transmitted in any from or by any means, electronically or mechanically, including photocopying, recording or any information storage or retrieval system, without either prior permission in writing from the publisher or a licence permitting restricted copying. In the United Kingdom such licences are issued by the Copyright Licensing Agency: 90 Tottenham Court Road, London W1P 9HE. Whilst the advice and information in this book is believed to be true and accurate at the date of going to press, neither the author[s] nor the publisher can accept any legal responsibility or liability for any errors or omissions that may be made. British Library Cataloguing in Publication Data Porter, Brain 1938– Carpentry and joinery. – 3rd ed. Vol. 1 1. Carpentry and Joinery. I. Title 694 ISBN 0 000 00000 0 Design and Typesetting by J&L Composition Ltd, Filey, North Yorkshire Printed and bound in Great Britain by Foreword ix Preface to the First Edition x Preface to the Second Edition x Preface to the Third Edition xi Acknowledgements xii CHAPTER ONE TIMBER 1 1.1 Growth and structure or a tree 1 1.2 Hardwood and softwood trees 4 1.3 Forest distribution (Source and supply of timber) 5 1.4 Conversion into timber 9 1.5 Size and selection of sawn timber 14 1.6 Structural defects (natural defects) 15 1.7 Drying timber 18 1.8 Grading timber 31 1.9 Processing squared sectioned timber 39 1.10 Structure of wood and identification of timber 44 1.11 Properties of timber 55 CHAPTER TWO ENEMIES OF WOOD AND WOOD BASED PRODUCTS 60 2.1 Non-rotting fungi (Sap-staining fungi) 61 2.2 Wood-rotting fungi 61 2.3 Attack by wood boring insects 66 CHAPTER THREE WOOD PRESERVATION AND PROTECTION 74 3.1 Paint and varnishes 74 3.2 Water-repellent exterior stains 75 3.3 Preservatives 75 3.4 Methods applying preservatives 78 3.5 Flame-retardant treatments 81 3.6 Other treatments 81 3.7 Health and safety 81 CHAPTER FOUR MANUFACTURED BOARDS AND PANEL PRODUCTS 84 4.1 Veneer plywood 84 4.2 Core plywood 89 4.3 Chipboard 90 4.4 Wood-cement particleboard 93 Contents 4.5 Oriented Strand Board OSB 94 4.6 Fibre building boards 96 4.7 Laminated plastics (Decorative Laminates) 101 4.8 Fibre cement building boards 105 4.9 Plasterboards 106 4.10 Composite boards 107 4.11 Conditioning wood-based boards and other sheet materials 107 4.12 Storage and stacking 108 4.13 Handling 109 4.14 Health & safety 109 CHAPTER FIVE HANDTOOLS AND WORKSHOP PROCEDURES 111 5.1 Measuring tools 111 5.2 Setting-out, marking-out & marking-off tools 112 5.3 Saws 117 5.4 Planes 122 5.5 Boring tools 128 5.6 Chisels (wood) 135 5.7 Shaping tools 137 5.8 Driving (Impelling) tools 138 5.9 Lever & withdrawing tools 146 5.10 Finishing tools & abrasives 147 5.11 Holding equipment (tools & devices) 149 5.12 Tool storage & accessory containers 153 5.13 Tool maintenance 159 CHAPTER SIX PORTABLE ELECTRIC MAINS POWERED HAND TOOLS & MACHINES 167 6.1 Specification plate (SP) 167 6.2 Earthing, insulation & electrical safety 168 6.3 Use of portable power tools 171 6.4 Electric drills (rotary) 171 6.5 Rotary impact (percussion) drills 174 6.6 Rotary hammer drills 175 6.7 Drill chucks 175 6.8 Electric screwdrivers 176 6.9 Sanders 177 6.10 Circular saws 178 6.11 Mitre saws 181 6.12 Combination saw bench and Mitre saws 183 6.13 Reciprocating saws 183 6.14 Planers 186 6.15 Routers 187 6.16 Nail and staple guns 191 CHAPTER SEVEN BATTERY-OPERATED (CORDLESS) HAND TOOLS 193 7.1 Method of use 193 7.2 Safe operation 193 vi Contents CHAPTER EIGHT CARTRIDGE OPERATED FIXING TOOLS (BALLISTIC TOOLS) 196 8.1 Types of tool 196 8.2 Cartridges 197 8.3 Fixing devices 198 8.4 Base materials 199 8.5 Fixing to concrete 201 8.6 Fixing into steel (usually structural mild steel sections) 202 8.7 Safe operation 202 CHAPTER NINE BASIC STATIC WOODWORKING MACHINES 205 9.1 Crosscutting machines 206 9.2 Hand feed circular saw benches 209 9.3 Dimension saw 211 9.4 Panel saws 212 9.5 Saw blades 213 9.6 Planing machines 216 9.7 Narrow bandsaw machines 222 9.8 Mortising machines 227 9.9 Sanding machines 229 9.10 Grinding machines 230 9.11 Workshop layout 232 9.12 Safety 232 CHAPTER TEN BASIC WOODWORKING JOINTS 235 10.1 Lengthening – end joints 235 10.2 Widening – edge joints 235 10.3 Framing – angle joints 238 CHAPTER ELEVEN WOOD ADHESIVES 245 11.1 Adhesive types 245 11.2 Adhesive characteristics 247 11.3 Application of adhesives 248 11.4 Safety precautions 248 CHAPTER TWELVE FIXING DEVICES 249 12.1 Nails 249 12.2 Wood screws 251 12.3 Threaded bolts 255 12.4 Fixing plates 255 12.5 Plugs 257 12.6 Combination plugs 258 12.7 Cavity fixings 261 12.8 Anchor bolts 262 Contents vii PRACTICAL PROJECTS 268 1: Porterbox – drop fronted tool box and saw stool 268 2: Portercaddy 272 3: Portercase 275 4: Porterdolly 276 5: Porterchest 277 6: Porterbench 282 7: Portertrestle – traditional saw stool 286 INDEX 293 viii Contents The craft of the carpenter and joiner, at least in those areas of the world where there is plentiful supply of timber is as old as history, and this book describes and illustrates for the benefit of students and others who care to read it, the changing techniques that continue to take place as our knowledge of wood and its working devel- ops. Standards controlling the quality of timber, timber based products, workmanship and safe working practices are continually being revised and harmonised to meet, not only our higher standards, but also those of Europe. Improved fastenings and adhesives have revolutionised joining techniques. Development in electrical battery technology has made possible the cord- less power tool. These improvements in the field of woodworking are a continual process, and so must be the updating of textbooks to reflect these changes. Brian Porter as a practicing Carpenter and Joiner, and a lecturer in wood trades is familiar with these changes, which have been incorporated into this revised edition, writ- ten to help wood trade students in the early stages of their chosen careers understand the techniques and principles involved in the safe and efficient working of timber and timber prod- ucts. A book maintaining the high standard Brian Porter set himself in his earlier publications, and which provides a wealth of information that will be helpful to all who have an interest in the working of wood. Reg Rose MCIOB, DMS, DASTE, FIOC former Assistant Principal, Leeds College of Building, UK Foreword I find it difficult to comprehend that after 20 years and two previous editions, this book is still in demand across the world. Its content has of course been periodically updated in keeping with current trends and legislation, but in essence, it remains the same. This new edition is printed in a similar format to the last one, but as can be seen from the con- tent page similarities end there. Its new design has taken into account the necessary theoretical job knowledge requirements of the modern car- penter and joiner. But, as with all my previous books, still maintaining a highly visual approach to its content. It would appear to some people that in recent years, many of our traditional hand tool skills have been replaced by the used of portable power tools. To some extent this may be partly true, but I believe that in the majority of cases, the professional carpenter and joiner would regard portable power tools more as an aid to greater productivity, rather than a replacement for traditional hand tools. Hand tools still play a vital part in our work, and it is for this reason that I haveagain included a large section devoted to their selection, safe use and application – together with several pieces of ancilliary equipment. Carpentry and Joinery volume 1, can also be used by students to help them grasp basic under- pinning knowledge of many, if not all of our every day work activities. It should be particulary helpful as a basis for acquiring a greater under- standing of the activities set out in the new editions of Carpentry and Joinery volumes 2 and 3. Unlike previous editions, the practical projects now appear within their own section towards the back of the book. To accompany the now well established ‘Porterbox’ system of containers, two additional projects have been added to this sec- tion – a ‘saw stool’ and ‘workbench’. I feel confident that the readers of this book will find it not only an asset to gaining a greater understanding of our craft, but also as a refer- ence manual for future use. Brian Porter 2001 Preface to the second edition The main difference between this book – the first of three new editions – is the overall size and format of the contents compared to the previous first edition (published in 1982). The most important reason for this change is that in the majority of cases text and illustration can now share the same or adjacent page, making refer- ence simpler and the book easier to follow. The most significant change of all is the new section on tool storage: Several practical innovative projects have been included which will allow the reader to make, either as part of his or her coursework or as a separate exercise, a sim- ple, yet practical system of tool storage units and tool holders – aptly called the ‘Porterbox’ system (original designs were first published in Woodworker magazine). Each chapter has been reviewed and revised to suit current changes. For example, this has meant the introduction of new hand tools, replacing or supplementing existing portable powered hand tools, and updating some woodworking machines. Educational and training establishments seem to be in a constant state of change; college and school based carpentry and joinery courses are no exception. As the time available for formal tuition becomes less, course content, possibly due to demands made by industry and the intro- duction of new materials together with a knowl- edge of any associated modern technology they bring with them, seems to be getting greater – making demands for support resource material probably greater than they have ever been. Distance learning (home study with profes- Preface sional support) can have a very important role to play in the learning process, and it should be pointed out that in some areas of study it is not just an alternative to the more formally struc- tured learning process, but a proven method in its own right. No matter which study method is chosen by the reader, the type of reading matter used to accompany studies should be easy to read and highly illustrative, and all subjects portrayed throughout this book meet that requirement. I hope therefore that this book is as well read, and used, by students of this most fulfilling of crafts. Brian Porter Leeds 1989 Preface to the first edition This volume is the first of three designed to meet the needs of students engaged on a course of study in carpentry and joinery. Together, the three volumes cover the content of the City and Guilds of London Institute craft certificate course in carpentry and joinery (course number 585). I have adopted a predominantly pictoral approach to the subject matter and have tried to integrate the discussion of craft theory and asso- ciated subjects such as geometry and mensura- tion so that their interdependence is apparent throughout. However, I have not attempted to offer instruction in sketching, drawing, and per- spective techniques (BS 1192), which I think are best left to the individual student’s school or college. Procedures described in the practical sections of the text have been chosen because they follow safe working principles – this is not to say that there are no suitable alternatives, simply that I favour the ones chosen. Finally, although the main aim of the book is to supplement school or college-based work of a theoretical and practical nature, its presentation is such that it should also prove invaluable to students studying by correspondence course (‘distance learning’) and to mature students who in earlier years may perhaps have overlooked the all-important basic principles of our craft. Brian Porter Leeds 1982 Contents xi I wish to thank: Reg Rose for proof reading the text, writing the foreword, and allowing me to reproduce many pieces of artwork we shared in previous joint authorship work as listed on the back of this book. Eric Cannell for editing and contributing material for Chapter 9 (Woodworking Machines). Peter Kershaw (Managing Director North Yorkshire Timber Co Ltd.) for his help and guidance. Colleagues and library staff at Leeds College of Building. I would also like to offer my gratitude to the following people and companies for their help and support by providing me with technical information and in many cases permission to reproduce item of artwork and/or photographs.Without their help many aspects of this work would not have been possible. Arch Timber Protection (formerly ‘Hickson Timber Products Ltd.) A L Daltons Ltd (Woodworking machines) American Plywood Association (APA) Black & Decker British Gypsum Ltd. Cape Boards Ltd. Cape Calsil Systems Ltd. Council of Forest Industries (COFI) CSC Forest Products (Sterling) Ltd. Denford Machine Tools Co Ltd. DEWALT Draper (The Tool Company). English Abrasive & Chemicals Ltd. Fibre Building Board Organisation Finnish Plywood International Fischer Fixing Systems. Forestor – Forest and Sawmill Equipment (Engineers) Ltd. Formica Ltd. Fosroc Ltd. G. F. Wells Ltd. (Timber Drying Engineers). Hilti Ltd. ITW Construction Products (Paslode) Kiln Services Ltd. Louisiana-Pacific Europe Makita UK Ltd. Mr Stewart J. Kennmar-Glenhill (Imperial College of Science and Technology, London) and David Kerr and Barrie Juniper of the Plant Science Department, Oxford, for contributing Figures 1.3 to 1.6 Mr. John Common (Kiln Services Ltd.) Neil Tools Ltd. Acknowledgements Nettlefolds (Woodscrews) Nordic Timber Council North Yorkshire Timber Co Ltd. Perstorp Warerite Ltd. Protim Ltd. Protimeter PLC Rabone Chesterman Ltd. Record Marples (Woodworking Tools) Ltd. Record Tools Ltd. Rentokil Ltd. Robert Bosch Ltd. (Power Tools Division) Stanley Tools, Stanley Works Ltd. Stenner of Tiverton Ltd. The Rawlplug Company Ltd. Timber Research and Development Association (TRADA), for information gleaned from TRADA Wood Information Sheets’. Trend Machinery & Cutting Tools Ltd. Wadkin Group of Companies PLC. Willamette Europe Ltd. Wolfcraft Tables 1.2 and 1.4 are extracted from BS 4471 Table 1.3 is extracted from BS 5450 Copies of the complete standards can be obtained from British Standards Institute, 389 Chiswick High Road, London W4 4AL. Copyright is held by the Crown and reproduced with kind permission of the British Standards Institute. With kind permission the line drawings in figures 9.1 (WIS 31). 9.3 (WIS 31). 9.7 (WIS 16). 9.25 (WIS 17). 9.26 (WIS 17). 9.27 (WIS 17). 9.30 (WIS 17). and 9.42 (WIS 31). were extracted from ‘Health & Safety Executive’ (HSE) Woodworking Information Sheets (WIS). The full information sheets are available from: HSE Books PO Box 1999 Sudbury Suffolk CO10 2WA Acknowledgements xiii This Page Intentionally Left Blank As part of their craft expertise, carpenters and joiners should be able to identify common, com- mercially used timbers and manufactured boards, to the extent that they also become aware of how they (as shown in figure 1.1) will respond to being: a cut by hand and machine, b bent, c subjected to loads, d nailed and screwed into, e glued, f subjected to moisture, g attacked by fungi, h attacked by insects, i subjected to fire, j treatedwith preservatives, flame retardants, sealants, etc., k in contact with metal. By and large, behaviour under these conditions will depend on the structural properties of the timber, its working qualities, strength and resist- ance to fungal decay (durability), insect attack, chemical make-up, and moisture content. 1.1 Growth & structure of a tree The life of a tree begins very much like that of any other plant – the difference being that, if the seedling survives its early stage of growth to become a sapling (young tree), it may dev- elop into one of the largest plants in the plant kingdom. The hazards to young trees are many and var- ied. Animals are responsible for the destruction of many young saplings, but this is often regar- ded as a natural thinning-out of an otherwise overcrowded forest, thus, allowing the sapling to mature and develop into a tree of natural size and shape. Where thinning has not taken place, trees grow thin and spindly – evidence of this can be seen in any overgrown woodland where trees have had to compete for the daylight nec- essary for their food production. With all natural resources that are in constant demand, there comes a time when demand outweighs supply. Fortunately, although trees require 30–100 years or more to mature, it is possible to ensure a continuing supply – prov- ided that land is made available and felling, (cut- ting down) is strictly controlled. This has meant that varying degrees of conservation have had to be enforced throughout some of the world’s largest natural forests and has led to the devel- opment of massive man-made forests (forest farming). Timber 1 Fig 1.1 Timber may respond differently to these treatments (a) (b) (c) (e) (d) (f) (g) (h) (k) (j) (i)(i) 1.1.1 Tree components There are three main parts: ● the root system, ● the stem or trunk, ● the crown. As can be seen from figure 1.2 these can vary with the type of tree (section 1.2). a Root system – The roots anchor the tree firmly into the ground, these can exceed the radius of the tree – size and spread depends on type and size of tree. The many small root hairs surrounding the root ends, absorb water and minerals, to form sap (see fig. 1.3). b Trunk (stem) – The stem or trunk conducts sap from the roots, stores food, and supports the crown. When the trunk is cut into lengths – they are called logs or boules. Timber is cut from this part of the tree (see fig. 1.3). c Crown – The crown consists of branches, twigs, and foliage (leaves). Branches and twigs are the lifelines supplying the leaves with sap (see fig. 1.3). 1.1.2 The food process (fig. 1.4) The leaves play the vital role of producing the tree’s food. By absorbing daylight energy via the green pigment (chlorophyll) in the leaf, they convert a mixture of carbon dioxide taken from both the air and sap from the roots into the nec- essary amounts of sugars and starches (referred to as food) while, at the same time releasing oxy- gen into the atmosphere as a waste product.This process is known as photosynthesis. However, during the hours of darkness, this action to some extent is reversed – the leaves take in oxygen and give off carbon dioxide, a process known as respiration (breathing). For the whole process to function, there must be some form of built-in system of circulation which allows sap to rise from the ground to the leaves and then to descend as food to be distrib- uted throughout the whole tree. It would seem that this action is due either to suction, induced by transpiration (leaves giving off moisture by evaporation), and/or to capillarity (a natural ten- dency for a liquid to rise within the confines of the cells – see Table 1.12) within the cell struc- ture of the wood. 1.1.3 Structural elements of a tree We will start from the outer circumference of the tree and work towards its centre. The following features are illustrated in fig. 1.5. a Bark – the outer sheath of the tree. It functions as: ● a moisture barrier, ● a thermal insulator, against extremes in temperature – both hot or cold. ● an armour plate against extremes of temperature, attack by insects, fungi, and animals. The bark of a well-established tree can usually withstand minor damage, although excessive ill treatment to this region could prove fatal. b Inner bark (bast or phloem) – Conducts food throughout the whole of the tree, from the leaves to the roots. c Cambium (fig. 1.6) – A thin layer or sleeve of cells located between the sapwood and the bast (phloem). These cells are responsible for the tree’s growth. As they are formed, they become subdivided in such a way that new cells are added to both sapwood and phloem, thus increasing the girth of the tree. d Growth ring – (Sometimes referred to as an annual ring) – wood cells that have formed around the circumference of the tree during its growing season. The climate and time of 2 Timber Crown Root system (often shallow) Narrow (needle) leaved (conifer) tree Root system (usually deep) Broadleaved tree Crown Stem (Trunk) Fig 1.2 General tree shape with their main parts year dictate the growth pattern. Each ring is often seen as two distinct bands, known as earlywood (springwood) and latewood (summerwood). Latewood is usually more dense than earlywood and can be recognised by its darker appearance. Growth rings are important because they enable the woodworker to decide on the suitability of the wood as a whole – either as timber for joinery (appearance & stability) or, its structural properties (strength & stability) as carcaseing timber. Growth & structure of a tree 3 HARDWOOD SOFTWOOD Foliage Branch Trunk Food Sap First grown Conduction Water and minerals Root system Fig 1.3 Growth of a tree (hardwood & softwood) e Rays – these may all appear (although falsely – as not many do) to originate from the centre (medulla) of the tree, hence the term medullary rays is often used to describe this strip of cells that allow sap to percolate transversely through the wood. They are also used to store excess food. Rays are more noticeable in hardwood than in softwood (see figure 1.83), and even then can be seen with the naked eye only in such woods as oak and beech. fig. 1.21 shows how rays may be used as a decorative feature once the wood has been converted (sawn into timber). f Pith (medulla) – the core or centre of the tree, formed from the tree’s earliest growth as a sapling. Wood immediately surrounding the pith is called juvenile wood, which is not suitable as timber. g Sapwood – the outer active part of the tree which, as its name implies, receives and conducts sap from the roots to the leaves. As this part of the tree matures, it gradually becomes heartwood. h Heartwood – the natural non-active part of the tree, often darker in colour than sapwood, gives strength and support to the tree and provides the most durable wood for conversion into timber. 1.2 Hardwood & softwood trees The terms hardwood and softwood can be very confusing, as not all commercially classified hardwoods are physically hard, or softwoods soft. For example, the obeche tree is classed as a hardwood tree, yet it offers little resistance to a saw or chisel etc. The yew tree, on the other hand, is much harder to work yet it is classified as a softwood.To add to this confusion we could be led to believe that hardwood trees are decid- uous (shed their leaves at the end of their grow- ing season) and softwood trees are evergreen (retain their leaves for more than one year), 4 Timber Light energy ChlorophyII Sa p Oxygen Oxygen Carbon dioxide Carbon dioxide Fo o d Fo o d S ap Daylight Darkness Fig 1.4 The process of photosynthesis (e) Rays (b) Inner bark or bast (phloem) (a) Bark (c) Cambium (f) Pith (medulla) (h) Heartwood (g) Sapwood Note: Sectional details of softwood (d) Growth ring (annual ring) Latewood (Summerwood) Earlywood (Springwood) Fig 1.5 Section through the stem/trunk which is true of most species within these groups, but not all!Table 1.1 identifies certain characteristics found in hardwood and softwood trees; however, it should be used only as a general guide. Hardwood and softwood in fact, refer to botanical differences in cell composition and structure (Cell types and their formation are dealt with in section 1.10). 1.2.1 Tree & timber names Common names are often given to trees, (and other plants) so as to include a group of similar yet botanically different species. It is these com- mon English names which are predominantly used in our timber industry. The true name or Latin botanical name of the tree must be used where formal identification is required – for example: Species (true name or Latin botanical name) Genus Common name (generic name Specific name English name or ‘surname’) (or ‘forename’) Scots pine Pinus sylvestris As a general guide, it could therefore be said that plants have both a surname and a forename, and, to take it a step further, belong to family groups of hardwood and softwood. Commercial names for timber often cover more than one species. In these cases, the botan- ical grouping is indicated by ‘spp’, telling us that similar species may be harvested and sold under one genus (singular of genera). Table 1.2 should give you a better idea how family groups are formed. The first division is into hardwoods and softwoods, next, into their family group, this is followed by their ‘Genera’ group, then finally their species. 1.3 Forest distribution (source and supply of timber) The forests of the world that supply the wood for timber, veneers, wood pulp, and chippings for par- ticle board, are usually situated in areas which are typical for a particular group of tree species. For example, as can be seen from figure 1.7, the conif- erous forests supplying the bulk of the world’s soft- woods are mainly found in the cooler regions of northern Europe, also Canada and Asia – stretch- ing to the edge of the Arctic Circle. Hardwoods, however, come either from a temperate climate (neither very hot nor very cold) – where they are mixed with faster-growing softwoods – or from subtropical and tropical regions, where a vast variety of hardwoods grow. There is increasing concern about the envi- ronmental issues concerning forest manage- ment, particularly with regard to over extraction of certain wood species – many of which are now protected. This concern has led to some suppliers certifying that their timber is from a Forest distribution (source and supply of timber) 5 Conduction of water and sap to foliage H e ar tw o o d sa p w o o d Xy le m ( w o o d ) D iv id es to p ro du ce n ew c el ls to fo rm p hl oe m & x yl em C am b iu m In n er b ar k o r b as t (p h lo em ) O u te r b ar k Note: Phloem - pronounced 'flo-em' Xylem - pronounced 'zi-lem' Fig 1.6 Function of the cambium layer non-protected or sustainable source. Suppliers are now being urged to specify that any timber or wood product used, should be able to present a copy of their Environmental Policy with regard to the products they are to provide. 1.3.1 Temperate hardwoods These hardwood trees are found where the cli- mate is of a temperate nature. The temperate regions stretch north and south from the tropical areas of the world, into the USSR, Europe, China and North America in the Northern Hemisphere, and Australia, New Zealand and South America in the Southern Hemisphere. The United Kingdom is host to many of these trees, but not in sufficient quantities to meet all its needs. It must therefore rely on imports from countries which can provide such species as oak (Quercus spp.), sycamore (Acer spp.), ash (Fraxinus. spp.), birch (Betula spp.), beech (Fagus spp.), and elm (Ulmus spp.) – which is now an endangered species due to Dutch elm disease. 1.3.2 Tropical and subtropical hardwoods Most tropical hardwoods come from the rain forests of South America, Africa, and South East Asia. Listed below are some hardwoods which are commonly used: African mahogany – West Africa (Khaya spp.) †Afrormosia (Pericopsis – West Africa elata) Agba – West Africa (Gossweiterodendron balsamiferum) 6 Timber Table 1.1 Guide to recognising hardwood and softwood trees and their use Hardwoods Softwoods (conifers) Botanical grouping Angiosperms Gymnosperms Leaf group Deciduous* and Evergreen† evergreen Leaf shape Broadleaf Needle leaf or scale like Seed Encased Naked via a cone General usage Paper and card Paper and card Plywood (veneers and core) Plywood (veneer and core) Particle board Particle board Timber – heavy structural, decorative joinery Fibre board Timber – general structural joinery Trade use Purpose made joinery Carpentry and joinery Shopfitting Note: *Within temperate regions around the world; †Not always, for example: larch trees are deciduous ‡American mahogany (Swietenia macrophylla) – Central & South America Gaboon (Aucoumea – West Africa klaineana) Iroko (Chlorophora – West Africa excelsa) Keruing (Dipterocarpus spp.) – South East Asia Meranti (Shorea spp.) – South East Asia Sapele – West Africa (Entandrophragma cylindricum) Teak (Tectona grandis) – Burma,Thailand Utile (Entandophragma utile) – West Africa N.B. Many of these species may have originated from tropical rain forest regions which the timber industry is trying to control as conservation areas: † � Trading restrictions ‡ � Protected species Also, see table 1.15 1.3.3 Hardwood use Hardwoods may be placed in one or more of the following purpose groups: Purpose group Use a Decorative natural beauty – colour and/or figured grain b General-purpose joinery and light structural c Heavy structural withstanding heavy loads 1.3.4 Softwoods Most timber used in the UK for carpentry and joinery purposes is softwood imported from Forest distribution (source and supply of timber) 7 Table 1.2 The family tree FAMILY Genera Genus GenusGenus SpeciesSpecies Species BEECH FAMILY GENUS Castanea Fagaceae SPECIES (sativa) Sweet chestnut Hardwood example GENUS Quercus SPECIES (robur) (rubra) (alba) OAKS CHESTNUT Common names English oak American white oak American red oak Common names GENUS Fagus SPECIES (robur) (rubra) (alba) BEECHES Common names European beech American beech PINE FAMILY GENUS Picea Pinaceae SPECIES (abies) (sitchensis) Softwood example GENUS Tsuga SPECIES (heterophylla) (canadensis) HEMLOCKS SPRUCES Common names Western hemlock Eastern hemlock Common names GENUS Pinus SPECIES (sylvestris) (contorta) PINES Common names Scots pine European redwood Lodge pole pine Norway spruce European whitewood Sitka spruce North America Canada & USA Douglas Fir Yellow Pine Western Hemlock Amabilis Fir Lodgepole Pine Eastern Spruce Western Red Cedar Maple Cherry Hickory Walnut Red Oak (American) White Oak (American) Ash Canadian Birch Central America & the Caribbean Pitch Pine American Mahogany Rosewood Lignum Vitre Central & South America Parana Pine Brazilian Mahogany Balsa Rosewood Lignum Vitae Greenheart West Africa African Mahogany Iroko Afrormosia Sapele Obeche Teak Central Europe European Oak Ash Walnut European Chestnut Elm United Kingdom Scots Pine Sitka Spruce Whitewood Douglas Fir Larch Alder Oak (English) Ash Birch Beech Sweden & Finland European Redwood European Whitewood Birch Russia European Redwood European Spruce (Whitewood) Ash Beech Philippines & Japan Lauan Oak South East Asia Teak Seraya Meranti Keruing Romin Jelutong Australasia Radiata Pine Eucalyptus Kauri Silky Oak Karri Jarrah Canada USA Florida Cuba Honduras PACIFIC OCEAN PACIFIC OCEAN South America Brazil West Africa Africa Ghana Nigeria Australia Indonesia India China Russia Asia NORTH SEA ATLANTIC OCEAN ARCTIC OCEAN Japan Malaysia Papua New Guinea Norway Sweden Finland Mexico KEY: Softwoods (Conifers) Temporate Hardwoods Mixed Softwoods (Conifers and Temporate Hardwoods) Tropical Hardwoods INDIAN OCEAN EQUATOREQUATOR Fig 1.7 Forestregions of the world Sweden, Finland, and the USSR. The most important of these softwoods are European red- wood (Pinus sylvestris), which includes Baltic redwood, and Scots pine, a native of the British Isles. As timber, these softwoods are collectively called simply ‘redwood’. Redwood is closely fol- lowed in popularity by European Whitewood, a group which includes Baltic Whitewood and Norway spruce (Picia abies) – recognised in the UK as the tree most commonly used at Christmas as the Christmas tree. Commercially, these, and sometimes silver firs are simply referred to as ‘whitewood’. Larger growing softwoods are found in the pacific coast region of the USA and Canada. These include such species as Douglas fir (Pseudotsuga menziesii) – known also as Columbian or Oregon pine, although technically not a pine.Western hemlock (Tsuga heterophylla), and Western red cedar (Thuj‘a plicata). Western red cedar is known for its durability and its resistance to attack by fungi. Brazil is the home of Parana pine (Araucaria angustifolia), which produces long lengths of virtually knot-free timber, which is however, only suitable for interior joinery purposes. 1.3.5 Forms of supply Softwood is usually exported from its country of origin as sawn timber in packages, or in bundles. It has usually been pre-dried to about 20% m.c. (Moisture content – see section 1.7). Packaged timber is to a specified quality and size, bound or bonded with straps of steel or plastics for easy handling, and wrapped in paper or plastics sheets. Hardwood, however, may be supplied as sawn boards or as logs to be converted (sawn) later by the timber importer to suit the customer’s requirements. 1.4 Conversion into timber Felling (the act of cutting down a living tree) is carried out when trees are of a commercially suitable size, having reached maturity, or for thinning-out purposes. Once the tree has been felled, its branches will be removed, leaving the trunk (stem) in the form of a log.The division of this log into timber sections is called conversion. What, then, is the difference between wood and timber? The word wood is often used very loosely to describe timber, when it should be used to describe either a collection of growing trees or the substance that trees are made of, i.e. the moisture-conducting cells and tissues etc. Timber is wood in the form of squared boards or planks etc. Initial conversion may be carried out in the forest whilst the log is in its green (freshly felled) state by using heavy, yet portable machines, such as circular saws or vertical and horizontal band- mills (see fig. 1.14). This leads to a reduction in transport cost, as squared sectional timber can be transported more economically than logs. Alternatively, the logs may be transported by road, rail, or water to a permanently sited sawmill. Were they are kept wet, either within a log pond, or with water sprinklers. 1.4.1 Sawing machines The type of sawing equipment used in a sawmill will depend on the size and kind of logs it han- dles. For example: a Circular saw (fig. 1.8) – small- to medium diameter hardwoods and softwoods. Figure 1.8 shows a rolling table log saw. The tables are available in lengths from 3.05 m to 15.24 m, and the diameter of saw could be as large as 1.829 m. b Vertical frame saw or gang saw (fig. 1.9) – small to medium-diameter softwoods. The log is fed and held in position by fluted rollers while being cut with a series of reciprocating upward-and-downward Conversion into timber 9 Fig 1.8 Circular saw moving). saw blades. The number and position of these blades will vary according to the size and shape of each timber section. Figure 1.10(a) illustrates the possible result after having passed the log through this machine once, whereas figure 1.10(b) shows what could be achieved after making a further pass. c Vertical band-mill (fig. 1.11) – all sizes of both hardwood and softwood. Logs are fed by a mechanised carriage to a saw blade in the form of an endless band, which revolves around two large wheels (pulleys), one of which is motorised. Figure 1.12 shows an example of how these cuts can be taken. d Double vertical band-saw (fig. 1.13) – small to medium logs. It has the advantage of making two cuts in one pass. e Horizontal band-saw (fig. 1.14) – all sizes of hardwood and softwood. The machine illustrated is suitable for work at the forest site, or in a sawmill. Conversion is achieved by passing the whole mobile saw unit (which travels on rails) over a stationary log, taking a slice off at each forward pass. The larger mills may employ a semi-computerised system of controls to their machinery, thus help- ing to cut down some human error and pro- viding greater safety to the whole operation. 10 Timber Fig 1.9 Vertical frame saw or gang saw (a) First cut (b) Second cut Fig 1.10 Possible cuts of a frame saw (see fig 1.13) Fig 1.11 Vertical band-mill 1 2 3 4 5 6 7 8 Fig 1.12 Band-mill cuts The final control and decisions, however, are usu- ally left to the expertise of the sawyer (machine operator). Timber which requires further reduction in size is cut on a resaw machine. Figure 1.15 shows a resawing operations being carried out, one a single unit, and the other using two machines in tandem to speed up the operation. Importers of timber in the United Kingdom may specialise in either hardwoods or softwoods, or both. Their sawmills will be geared to meet their particular needs, by re-sawing to cus- tomers’ requirements. Hardwood specialists usually have their own timber drying facilities. Conversion into timber 11 Bansaw blades Fig 1.13 Double vertical band-saw Fig 1.14 ‘Forester-150’ horizontal band-mill – through and through sawing Fig 1.15 Resawing timber 1.4.2 Method of conversion The way in which the log is cut (subdivided) will depend on the following factors: ● type of sawing machine, ● log size (diameter or girth) ● type of wood, ● condition of the wood – structural defects etc.(see section 1.6), ● proportion of heartwood to sapwood, ● future use – structural, decorative, or both. Broadly speaking, the measures taken to meet the customer’s requirements will (with the exception of the larger mills) be the responsibil- ity of the experienced sawyer (as mentioned ear- lier), whose decision will determine the method of conversion, for example: a Through-and-through-sawn (fig. 1.16) In this method of conversion, parallel cuts are made down the length of the log, producing a number of ‘quarter’ and ‘tangential’ sawn boards (figs 1.17 and 1.19). The first and last cuts leave a portion of wood called a ‘slab’. This method of conversion is probably the simplest and least expensive. NB. Cuts may be made vertically or horizontally depending on the type of machine. b Tangential-sawn (Plain sawn) – figure 1.17 shows that by starting with a squared log, tangential-sawn boards are produced by working round the log, by turning it to produce boards, all of which (except the centre) have their growth rings across the boards’ width. Figure 1.18 shows alternative methods leaving a central ‘boxed heart’ Although tangential-sawn sections are 12 Timber Slab Fig 1.16 Through and through sawn (producing plain and quarter sawn timber) Plain sawn timber - growth rings meet the face of the board at an angle less than 45° Fig 1.17 Tangentially sawn (producing ‘plain sawn’ or ‘flat sawn’ timber – except for heartboards) Fig 1.18 Dividing the log to produce plain sawn timber and a boxed heart subject to cupping (becoming hollow across the width) when they dry, they are the most suitable sections for softwood beams, i.e. floor joists, roof rafters, etc., which rely on the position of the growth ring to give greater strength to the beam’s depth. c Quarter (radial) or rift-sawn (fig. 1.19) – this method of conversion can be wasteful and expensive, although it is necessary where a large number of radial or near radial-sawn boards are required. Certain hardwoods cut in this fashion, producebeautiful figured boards (fig. 1.21), for example, figured oak, as a result of the rays being exposed (fig. 1.5). Quarter-sawn boards retain their shape better than tangential-sawn boards and tend to shrink less, making them well suited to good-class joinery work and quality flooring. The resulting timber, with the exception of that which surrounds the ‘heart wood’ shown in table 1.3 will either be: ● Tangentially (plain) sawn. ● Quarter sawn or Rift sawn. Conversion into timber 13 Quartered log WasteQuarter/rift - sawn methods Radial quarter sawn Acceptable quarter sawn not less than 45˚ Close-up Fig 1.19 Quarter (radial) or rift sawn timber Table 1.3 Comparison between ‘plain’ and ‘quarter’ sawn timber Advantages Disadvantages Plain sawn Economical conversion Tends to ‘cup’ (distort) on Ideal section for drying due to shrinkage – softwood beams (‘cupping’ is its natural Can produce a decorative pattern of shrinkage) pattern (flower or flame figure) on the tangential face of the timber with distinct growth rings – see Figures 1.21 and 1.86c Quarter sawn Retains it shape better Expensive form of during drying conversion Shrinkage across its width Conversion methods can half of that of plain sawn be wasteful timber Ideal selection for flooring with good surface wearing properties Produces a decorative radial face (e.g. Silver Figure) on hardwoods with broad ray tissue, see figures 1.21 and 1.86 b and c 1.4.3 Conversion geometry (Fig. 1.20) Knowing that a log’s cross-section is generally just about circular, the above-mentioned saw cuts and sections could be related to a circle and its geometry. For example, timber sawn near to a ‘radius’ line will be radial-sawn. quartered logs (divided by cutting into four quarters) or quad- rants. Similarly, any cut made as a tangent to a growth ring would be called tangentially sawn. The ‘chords’ are straight lines, which start and finish at the circumference; therefore a series of chords can be related to a log that has been sawn ‘through-and-through’, ‘plain sawn’ or ‘flat sawn’. It should be noted that the chord line is also used when cuts are made tangential to a growth ring, and when the log is cut in half. 1.4.4 Decorative boards Figure 1.21 gives two examples of how wood can be cut to produce timber with an attractive face. Quarter sawn hardwoods with broad rays can produce nicely figured boards. For example, quarter sawn European Oak is well known for its ‘Silver figure’ when sawn in this way. Tangentially sawn softwoods with distinct growth rings can produce a flame like pattern on their surface – known as ‘Flame figuring’. Further examples can be see in figure 1.86. 1.5 Size and selection of sawn timber) Sawn timber is available in a variety of cross- sectional sizes and lengths to meet the different needs of the construction and building industry. By adopting standard sizes, we can reduce the time spent on further conversion, subsequent wastage, and the inevitable build-up of short ends or off-cuts (off-cuts usually refers to waste pieces of sheet materials), thereby making it possible to plan jobs more efficiently and economically. 1.5.1 Softwoods Depending on whether the suppliers are from North America or Europe, stated cross- section sizes can vary. Canadian mills, unlike European mills, may not make any allowance in their sizes for any shrinkage when their timber is dried. Timber shrinks very little in its length, so allowance provisions are not necessary. Table 1.4(a) shows the cross sectional sizes of sawn softwood normally available in the U.K. and table 1.4(b) their cut lengths. 1.5.2 Hardwoods As shown in figure 1.22 different profiles are available to suit the end user. Dimentioned sawn stock sizes as shown in table 1.5 may be avail- able, but this will depend on species and local availability. 14 Timber Segment (slab) Plain sawn Chords Quarter Sawn QuadrantR ad iu s Diameter Circumference ArkL og Ta ng en t Ta ng en t 90 � Norm al Fig 1.20 Conversion geometry Rays Exposed earlywood Exposed latewood Exposed broad ‘ray’ tissue Plain sawn Douglas fir or European Redwood Quarter sawn Oak or Beech Fig 1.21 Decorative boards (other examples are shown in fig. 1.86) Figures 1.23 to 1.27 show defects that may be evident before, and/or during conversion. Most of these defects have little, if any, detrimental effect on the tree, but they can degrade the tim- ber cut from it, i.e. lower its market value. 1.6.1 Reaction wood (fig 1.23) This defect is the result of any tree which has had to grow with a natural leaning posture, this may be as a result of having to resist strong prevailing winds, or having to established itself on sloping ground. These trees resist any pressure existed upon them by attempting to grow vertically with Structural defects (natural defects) 15 Table 1.4 Sawn sizes of softwood timber (a) Customary target sizes of sawn softwood Thickness Width (mm) (mm) 75 100 115 125 138 150 175 200 225 250 275 300 16 � � � � 19 � � � � 22 � � � � 25 � � � � � � � � � � 32 � � � � � � � � � � � 38 � � � � � � � � � � � � 47 � � � � � � � � � 50 � � � � � � � � � 63 � � � � � � 75 � � � � � � � � � 100 � � � � � � � 150 � � � 250 � 300 � Note: Certain sizes may not be obtainable in the customary range of species and grades which are generally available. Permitted deviation of cross-sectional sizes at 20% moisture content. ● for thickness and widths �100 mm [�3 �1 ] mm; ● for thickness and widths �100 mm [�4 �2 ] mm. Target size of 20% moisture content. (b) Customary lengths of sawn softwood 1.80 2.10 3.00 4.20 5.10 6.00 7.20 2.40 3.30 4.50 5.40 6.30 2.70 3.60 4.80 5.70 6.60 3.90 6.90 Note: Lengths of 5.70 m and over may not be readily available without finger jointing See Table 1.5 5.7 00 –m ay go up to 7.2 00 1.8 00 30 0 m m Inc rem ent s (st age s) Dimensioned stock Random width - one straight edge Random width - waney edged Fig 1.22 Profiles of hardwood sections 1.6 Structural defects (natural defects) (c) added supportive wood growth to their stem. This extra growth will be formed in such a way that the stem will take on an eccentric appear- ance around the stem, which, with softwood is on the side of the tree that is being subjected to compressive forces – this wood is known as a compression wood. Hardwoods on the other hand, produce extra wood on the side likely to be stretched, since this is the side in tension. This wood is known as tension wood. In both these cases the wood is unsuitable as timber since it would be unstable went dried and par- ticularly hazardous when processed. Collectively, both compression and tension wood are known as reaction wood. 1.6.2 Heart shake (Star shake – Fig. 1.24(a)) Shake (parting of wood fibres along the grain) within the heart (area around the pith) of the tree caused by uneven stresses, which increase as the wood dries. A star shake is collection of shakes radiating from the heart. 16 Timber Lean due to prevailing wind Lean due to steep natural propogation Compression side (a) Compression woods (Softwoods) (b) Tension woods (Hardwoods) Tension side Section A-ASection B-B A A B B Fig 1.23 Reaction wood (e) (f) (g) (b) (a) (d) (c) Fig 1.24 Structural (natural) defects Table 1.5 Basic guide sizes of sawn Hardwood Thickness Width (mm) (mm) 50 63 75 100 125 150 175 200 225 250 300 19 � � � � � 25 � � � � � � � � � � � 32 � � � � � � � � � � 38 � � � � � � � � 50 � � � � � � � � 63 � � � � � � 75 � � � � � � 100 � � � � � � Note: Designers and users should check the availability of specified sizes in any particular species 1.6.3 Ring shake (Cup shake – Fig. 1.24(b)) A shake which follows the path of a growth ring. Figure 1.24 (c) shows the effect it can have on a length of timber. 1.6.4 Natural compression failure (upset – fig. 1.24(e)) Fracturing of the fibres; thought to be caused by sudden shock at the time of felling or by the tree becoming over-stressed(during growth) – possi- bly due to strong winds etc. NB. Other names for this defect include ‘thunder shake’ or ‘lightning shake’. 1.6.5 Rate of growth fig. 1.24(d)) The number of growth rings per 25 min, can with softwoods determine the strength of the timber. 1.6.6 Wane (Waney-edge – fig. 1.24(f)) The edge of a piece of timber that has retained part of the tree’s rounded surface, possibly including some bark. 1.6.7 Encased bark (fig. 1.24(g)) Bark may appear inset into the face or the edge of a piece of timber. 1.6.8 Sloping grain (fig. 1.25) The grain (direction of the wood fibres), slopes sharply in a way that can make load-bearing tim- bers unsafe, e.g. beams and joists. Figure 1.25a shows possible source. Figure 1.25b a method of testing for sloping grain. Figure 1.25c how sloping grain could be respon- sible for pre-mature fracturing of a beam. 1.6.9 Knots As shown in figure 1.26 where the tree’s branches join the stem they become an integral part of it. The lower branches are often trimmed off by for- est management during early growth, this encour- ages ‘clear wood’ to grow over the knot as the tree develops. Figure 1.27 shows how knots may appear in the sawn timber. The size, type, location, and number of knots, are controlling factors when the timber is graded for use. Some of the terms used to describe knots are: ● Dead knots – If a branch is severely damaged, that part adjoining the stem will die and may eventually become enclosed as the tree develops – not being revealed until Structural defects (natural defects) 17 a) Timber sawn from bent log b) Testing for slope of grain by pulling a swivel handled scribe along the grain Kg c) Premature Fracture Fig 1.25 Sloping grain Knots radiating from 'Pith' A B C Face splay or spike knot Edge knot Edge splay or spike knot Arris Knot Face knot Loose 'dead' margin knot Branch Fig 1.26 Knots in relation to branches and stem Location conversion into timber. Note: these knots are often loose, making them a potential hazard whenever machining operations are carried out. ● Knot size – Larger the knot greater the strength reduction of the timber. ● Knot location – Knots nearer the edges (margins) of the beam are generally going to reduce the strength properties of timber, rather than those nearer the centre. ● Number of Knots – Generally the greater the distance between the knots the better. ● Knot types – Knots appearing on the surfaces of timber take many forms the names reflect their position, for example: ● Face knots ● Margin knots ● Edge knots ● Arris knots ● Splay or spike knots 1.6.10 Resin (Pitch) pocket An a opening, following the saucer shape of a growth ring containing an accumulation of resin. Apparent in many softwoods, mainly in spruces – it may appear as a resinous streak on the sur- face of timber. In warm weather sticky resin may run down vertical members. When the resin dries it takes on a resinous granular form which can be scraped away. 1.7 Drying timber Timber derived from freshly felled wood is said to be green, meaning that the cell cavities contain free water and the wall fibres are saturated with bound water (fig. 1.33), making the wood heavy, structurally weak, susceptible to attack by insects and/or fungi, also unworkable. Timber in this condition is therefore always unsuitable for use. The amount of moisture the wood contains as a percentage of the oven-dry weight, is known as the moisture content (m. c.), and the process of reducing the m.c is termed drying. The main object of drying timber is therefore to: ● reduce its weight, ● increase its strength properties, ● increase its resistance to fungal and attack by some insects, 18 Timber Whorl (circular set) of branches knots distributed knot cluster Fig 1.27 Knot condition, size and distribution Depth D 0.25( � )D₁ 0.25( � )D₁ Margin areas Large knot Pin knots Dead knot Live/sound or tight-knot Loose dead knot ● provide stability with regards to moisture movement, ● increase workability for machine and hand tools ● enable wood preservative treatments to be applied, (with the exception of those applied by diffusion – section 3.4.2) ● enable fire retardant treatments to be applied ● enable surface finishes to be applied ● enable adhesives to be applied, ● reduce the corrosive properties of some woods, ● reduce heat conductivity thereby increase thermal insulation properties, and produce timber with a level of moisture con- tent acceptable for its end use. Examples are given in figure 1.28 and table 1.6. The drying process, (sometimes called ‘sea- soning’), is usually carried out by one of three methods: a Air-drying (natural drying), b Kiln-drying (artificial drying), c Air-drying followed by kiln-drying. All three methods aim at producing timber that will remain stable in both size and shape – the overriding factor being the final moisture con- tent, which ultimately controls the use of the timber. Although outside the scope of this book other drying methods include: ● forced-air drying, ● climate chambers, ● dehumidifiers, ● vacuum drying, Because the object of drying timber is to remove water from the cells (fig. 1.33), moisture content is considered first. 1.7.1 Moisture content (m.c) As already expressed, the moisture content of wood is the measured amount of moisture within a sample of wood expressed as a percentage of its dry weight. If the weight of water present exceeds that of dry wood, then moisture con- tents of over 100% will be obtained. There are several methods of determining moisture content values, but we will only be con- sidering the following two methods: ● the traditional oven-drying method, and ● using modern electrical moisture meters and probes, a Oven-drying method (fig. 1.29) – a small sample cut from the timber which is to be dried (see fig. 1.43) is weighed to determine its ‘initial’ or ‘wet’ weight. It is then put into an oven with a temperature of 103�C 2�C until no further weight loss is recorded, its weight at this stage being known as its ‘final’ or ‘dry’ weight. Once the ‘wet’ and ‘dry’ weights of the sample are known, its original moisture content can be determined by using the following formulae: Moisture content % � Initial (wet weight (A)) � final (dry weight (B)) � 100 Final or dry weight (B) Or Initial (wet weight (A)) MC % �1 � 100 Final or dry weight (B) For example, if a sample has a wet weight of 25.24 g (A) and a dry weight of 19.12 g (B), then: A � B MC % � � 100 B 25.24 g � 19.12 g � 100 � 32% 19.12 g Drying timber 19 N.B. Wood with a 20% + M.C. is liable to attack by fungi 15 to 20% 8% 12%17% 12% 18% Fig 1.28 Moisture content of wood products in various situations Or A MC % � �1 � 100[( B ) ] 25.24 g MC % � �1 � 100 � 32%[( 19.12 g ) ] b Electrical moisture meters (fig. 1.30) These are battery-operated instruments, which usually work by relating the electrical resistance of timber to the moisture it contains. Moisture content is measured by pushing or driving (hammer-type) two electrodes into the timber. The electrical resistance offered by the timber is converted to a moisture content which can be read off a calibrated digital scale of the meter, the lower the resistance, the greater the moisture content, since wet timber is a better conductor of electricity than dry. Meters generally will only cope with accuracy, for timber with moisture content between 6 and 28%. Above this point (the fibre-saturation point) there will be little or no change in electri- cal resistance. With the exception of the small hand held models (fig 1.31) useful for making 20 Timber Table 1.6 Moisture content of timber in relation to its end use 10 5 0 % Shrinkage in relation to section and moisture content (N.B. Guide only as there can be great variations between species) MC %MC % Radial shrinkage (See section 1.7.3) Internal joinery–occasionally heated buildings A rt if ic ia l d ry in g ( k iln s ) n e c e s sa ry A ir d ry in g c a n b e u s e d Internal joinery–intermittently heated buildings Internal joinery–continuously heated buildings Internal joinery close to heat source Oven dry 1 0 2 3 4 7 6 8 9 12 11 13 14 17 16 18 19 22 21 23 27 26 28 25 20 15 10 5 24 Internal joinery–continuously highly heated buildings e.g.hospitals, offices, etc External joinery and structural timbers Above this line dry rot spores may germinate Carcassing timber (to average 20% MC) Shrinkage begins here Pressure preservative treatment with creosote or CCA, a flame retardent treatment Tangential shrinkage (see Section 1.7.3) 2 4 6 8 10 25 20 15 spot checks on site. Moisture meters are in two parts (fig 1.32): ● The meter itself with both a numerical scale and pointer, or digital readout – provision will be made for adjustment to suit different wood species – this part will also have provision for housing the batteries. It may also, like the one shown in figure 1.32 have integral pins to allow surface readings to be taken. ● Spiked electrodes (probes) set into an insulated hand-piece, with provision for attaching it to the meter via a detachable cable. Moisture meter systems are more than just a useful aid for making spot checks – in fact in the Drying timber 21 Dried sample * (See Fig. 1.43 -'Cutting oven samples') B Fig 1.29 Method of determining moisture content by oven drying a small sample of timber (also see fig 1.43) Oven drying % M.C. = x100 A – B B Wet sample * A Small current from battery INPUT OUTPUT Minimal current flow - good resistance offered INPUT OUTPUT Small 'wet' timber sample Small 'dry' timber sample Current flow - little resistance offered Conductivity increases with any increase in moisture content Analogue Digital Hammer action Push-in-type electrodes (thin timber sections) Hammer-in-type electrodes (thicker timber sections) Needles (electrodes) Wet zone (high moisture content) Dry zone (lower moisture content) Approximate range of recordable moisture content 6-30% Fig 1.30 Battery operated moisture meter practical sense, when used in conjunction with the timber drying procedures of air and kiln dry- ing, they can be better than the oven-drying method.Whenever a moisture meter is used it is important that: a probes can reach the part of the timber whose moisture content is needed (depends on the sectional size of the timber and the type of instrument); b allowance must be made for the timber species – timber density can affect the meter’s reading; c the temperature of the timber is known – meter readings can vary with temperature; d certain chemicals are not present in the timber, for example, wood preservatives or flame-retardant solutions. Tests on moisture content may be necessary when sorting large batches of timber, or check- ing the condition of assembled or fixed carpen- try and joinery, particularly, if a fungal attack is in evidence or suspected – in which case a mois- ture meter would be invaluable. 1.7.2 Moisture removal Before considering the two main drying tech- niques, let us try to understand how this loss of moisture may effect the resulting timber. Figure 1.33 illustrates how moisture is lost naturally, and the effect it can have on a timber section if moisture is then reintroduced. We already know that green timber contains a great amount of water. This water is con- tained within the cell cavities – we call this free water, because it is free to move around from cell to cell. The water contained within the cell walls is fixed (chemically bound to them), and is therefore known as bound water or bound moisture. As you will know the air we breathe contains varying amounts of moisture: the amount will depend on how much is suspended in the air as vapour at that point in time, which in turn will depend on the surrounding air temperature. As the air temperature increases, so does its capac- ity to absorb more moisture as vapour, until the air becomes saturated, at which point we are very aware of how humid it has become. It is therefore this relationship between air tempera- ture, and the amount of moisture the air can hold that we call relative humidity. If the air, surrounding the timber has a vacant capacity for moisture, it will take up any spare moisture from the wood until, eventually, the moisture capacity of the air is in balance, or equilibrium, with that of the timber.When stable 22 Timber Fig 1.31 Hand held ‘mini’ moisture metre by ‘protimeter’ (with kind permission from Protimeter Ltd) Fig 1.32 Protimeter diagnostic timber master – two part moisture meter (with kind permission from Protimeter Ltd) conditions are reached we can say an equi- librium moisture content (EMC) has been achieved. This process will of course act in reverse, because wood is a hygroscopic mater- ial, which means that it has the means, provided the conditions (those mentioned above), are suitable, to pick up from and shed moisture to its surrounding environment. Any free water will leave first, via tiny perfora- tions within the cell walls. As the outer cells of the timber start to dry, they will be replenished by the contents of the inner cells, and so on, until only the cell walls remain saturated.The timber will start to shrink at this important stage of drying, known as the fibre saturation point (FSP) when about 25% to 30% m.c. (table 1.6) will be reached. Beyond fibre saturation point (FSP), drying out bound water can be very lengthy process if left to take place naturally. To speed up the process, artificial drying techniques will need to be employed. It is worth pointing out at this stage, that it is possible for timber in a changeable environment to remain stable if moisture absorption can be prevented. This may be achieved by one of two methods: 1 Completely sealing all its exposed surfaces, 2 Using a micro-pore sealer that prevents direct entry of water from outside but allows trapped moisture to escape. All timber must of course be suitably dried before any such treatments are carried out. Drying timber 23 HIGH MOISTURE (M) CONTENT EQUILIBRIUM (depends on environment) INCREASED MOISTURE CONTENT m M E E E E m m m mm Shrinkage ExpansionNo shrinkage Cell Cell cavity-free water GREEN DRYING DRY (seasoned) Moisture absorption M.C. retained by sealing pores with paint, varnish etc.M/m = moisture E = evaporation Cell wall (Bound moisture) Fibre saturation Fig 1.33 Basic principles of moisture movement 1.7.3 Wood shrinkage Whether natural or artificial means are used to reduce the moisture content of timber, it will inevitably shrink. The amount of shrinkage will depend on the reduction below its FSP. Probably the most important factor, is the relationship between the differing amounts of shrinkage, compared with the timbers length (longitudinally), and its cross-section (transverse section), whether it is plain saw (tangentially) or quarter saw (radially). And how, as shown in fig- ure 1.34 we can view different proportions of shrinkage, for example: a tangentially – responsible for the greatest amount of shrinkage b radially – shrinkage of about half that of tangential shrinkage c longitudinally – hardly any shrinkage. We call varying amounts of shrinkage differen- tial shrinkage. Figure 1.35 shows how shrinkage movement takes place in relation to the direction of the wood cells situated across the end grain. As a result of this movement, we can expect some sec- tions of timber to distort in some way as mois- ture is removed from the cells to below fibre sat- uration point. The resulting shapes of distorted timber sections will depend on where the timber was cut out of the log during its conversion into timber. Figure 1.36 should give some idea as to how certain sections of timber may end up after being dry – reference should be made to section 1.7.8 which itemises various drying defects. 1.7.4 Air drying (natural drying) Oftencarried out in open-sided sheds, where the timber is exposed to the combined action of circulating air and temperature, which lifts and drives away unwanted moisture by a process of evaporation (similar to the drying of clothes on a washing line). A suitable reduction in m. c. can take many months, depending on: 24 Timber a tangentially - responsible for the greatest amount of shrinkage b radially - shrinkage of about half that of tangential shrinkage c longitudinally - hardly any shrinkage 'C' (c) Length (longitudinal) minimal shrinkage (least amount) Plain saw 'A' 'B' Quarter sawn 'C' 'C' (a) Tangent Tangentially - the greatest amount of shrinkage (b) Radial Radially shrinkage about half the amount of tangential Fig 1.34 Proportions of wood shrinkage Radial cell shrinkage reduced to about half of tangential cell movement - this restriction is due in part to lack of movement of ray cells radially Greatest shrinkage accross the cells tangentially Ray cells (little or no movement radially)Axial cells (little or no Movement) Fig 1.35 Shrinkage movement in relation to direction of wood cells (exaggerated view of end grain) a the drying environment and amount of exposure, b the type of wood (hardwood or softwood), c the particular species, d the timber thickness. The final m. c. obtained can be as low as 16 % to 17 % in summer months and as high as 20 % or more during winter. It would therefore be fair to say that this method of drying timber is very unreliable. A typical arrangement for air-drying is shown in figure 1.37, where the features numbered are of prime importance if satisfactory results are to be achieved. They are as follows: 1 Timber stacks (piles of sawn timber), must always be raised off the floor, thus avoiding rising damp from the ground. Stacked correctly (fig. 1.39). Concrete, gravel, or ash will provide a suitable site covering. 2 The area surrounding the shed must be kept free from ground vegetation, to avoid conduction of moisture from the ground. 3 Free circulation of air must be maintained throughout the stack – the size and position of ‘sticks’ will depend on the type, species, and section of timber being dried. 4 The roof covering must be sound, to protect the stacks from adverse weather conditions. The success of air-drying will depend on the fol- lowing factors: a weather protection, b site conditions, c stacking as shown in figure 1.39, d atmospheric conditions. a Weather protection Except when drying certain hardwoods which can be dried as an open-piled ‘boule’ (the log being sawn through-and-through and then reassembled into its original form – see ‘Stacking’), a roof is employed to protect the stack from direct rain or snow and extremes in temperature. Its shape is unimportant, but cor- rugated steel should be avoided in hot climates because of its good heat-conducting properties that would accelerate the drying process. Roof coverings containing iron are liable to rust and should not be used where species of a high tannin content (such as Oak, Sweet chestnut, Afrormosia, Western red cedar, etc.) are being Drying timber 25 Minimal shrinkage distortion Diamonding Cupping Fig 1.36 Shrinkage – its possible effect on timber IMPORTANT ELEMENTS: 1. Risen off the ground - no rising damp. 2. Clear of ground vegetation. 3. Free circulation of air. 4. Protection from the weather. Sticks (stickers) at 0.600 to 1.200 4 3 2 1 Fig 1.37 Air drying shelter and stack build-up dried, otherwise iron-staining is possible where roof water has dripped on to the stack. Shed sides may be open (fig. 1.37) or slatted. Adjustable slats enable the airflow to be regu- lated to give greater control over the drying process. End protection can also be provided by this method – unprotected board ends are liable to split as a result of the ends drying out before the bulk of the timber, hardwoods like oak and beech are particularly prone to this problem. Other methods used to resist this particular sea- soning defect are shown in figure 1.38, namely: ● treating the end grain with a moisture-proof sealer – for example, bituminous paint or wax emulsion, etc.; ● nailing laths over the end grain – thick laths should be nailed only in the middle of the board, to allow movement to take place; ● hanging a drape over the end of the boule or stack. b Site conditions As previously stated the whole site should be well drained, kept free from vegetation by blind- ing it with a covering of ash or concrete, and kept tidy. If fungal or insect attack is to be discouraged, ‘short ends’ and spent piling sticks should not be left lying around. Sheds should be sited with enough room left for loading, unloading, carrying out routine checks, and other operations. c Stacking the timber (fig 1.39) The length of the stack will be unlimited (depending on the timber lengths), but its height must be predetermined to ensure stability, and the stack must be built to withstand wind. The width should not exceed 2 metres, otherwise crossed airflow may well be restricted to only one part of the stack, however, adjacent stacks can be as close to each other as 300 mm. d Piling sticks (stickers) Piling sticks (stickers) should never be made from hardwood, or they could leave dark marks across the boards (fig 1.52). Their size and dis- tance apart will vary, according to board thick- ness, drying rate, and species. They must always be positioned vertically one above the other, otherwise boards may ‘bow’ as shown in figure. 1.39(a). Stacks with boards of random length may require an extra short stick as shown in fig- ure 1.39 (b). 26 Timber Roll-up drape (tarpaulin ect.) Moisture-proof coating-bituminous paint or wax emulsion Allows wood slab to shrink Thin lath - Alowed to buckle Thin lath - three nails Thick lath - centre-nails Fig 1.38 End grain protection of timber or boule will help prevent end splitting Softwood sticks 25mm x 13mm to 25mm x 25mm at intervals of 0.600 to 1.200 centres - depending on board thickness and drying rate Short sticks Not in-line In-line No support Sticks in-line (a) (b) Fig 1.39 Build-up of stack Figure 1.40 shows how boules are piled in log form. Certain hardwoods are often dried in this way, to ensure that the dried boards will match one another in colour and grain figure. e Atmospheric conditions in general It is impracticable to generalise on an ideal dry- ing environment when atmospheric conditions can vary so much between seasons and coun- tries. It is, however, important that whatever means are used to regulate the drying rate of timber, should be directed at achieving unifor- mity throughout the whole stack – otherwise, the timber could become distorted or suffer other defects due to uneven shrinkage (see ‘Drying defects’), section 1.7.8. 1.7.5 Kiln drying (artificial drying) These kilns are generally large closeable cham- bers into which stacks of green timber are manoeuvred via a system of trolleys to undergo a controlled method of drying. Kilns of this nature dramatically reduce the drying time compared to air drying methods, as they take a matter the days instead of months. They vary in their construction, size and function. There are those where the stacks of timber remain static (stationary) until required moisture content level is reached; these are known as compartment kilns. Then, there is a method were timber is moved in stage through a tunnel dryer, known as a progres- sive kiln. Both types of kiln will require means of providing controlled: ● heat, ● ventilation, ● humidification, ● air circulation. Heat is often provided via steam or hot water pipes. The fuel used to fire the boiler may be of wood waste, oil, gas, or coal. Ventilation is achieved by adjustable openings strategically positioned in the kiln wall or roof. Alternatively, a dehumidifier can be used to extract unwanted moisture and channel it out- side the kiln in the form of water – thus con- serving heat and reducingfuel costs. When the amount of moisture leaving the wood is insufficient to keep the humidity to the required level, jets of steam or water droplets may be introduced into the chamber. Air circulation is promoted by a single large fan or a series of smaller fans, located either above or to the side of the stack, depending on the kiln type. All the above must be controlled in such a way that the whole process can be programmed to suit the species, thickness, and condition of the wood. Prescribed kiln schedules are available to take the wood through the various stages of moisture content (say from ‘green’ to 15% m.c.). These are listed in descending order for the appropriate kiln temperature and relative humidity needed at each stage of drying. The temperature and the amount of water vapour in the air entering the stack are measured with a kiln hygrometer, to assess the relative humidity of the air, which will determine the rate at which the wood dries. Relative humidity at a particular temperature is expressed as a percentage (fully saturated air having a value of 100% RH). Less water vapour at the same temperature means a lower relative humidity; therefore by lowering the relative Drying timber 27 Raised off ground Sticks 13mm to 19mm thick - vertically in-line Fig 1.40 Hardwood boules – piled in log form humidity, drying potential is increased. It must also be remembered that the higher the air tem- perature, the greater its vapour-holding capacity. Very broadly speaking, it can be said that kiln drying involves three stages: i heating up the wood without it drying – low heat, high humidity; ii starting and continuing drying – increased heat, less humidity; iii final stages of drying – high heat, slight humidity. Kiln samples However, kiln adjustments required to satisfy the schedules cannot be made until the correct moisture content of the stack as a whole is known. This may mean sample testing. Sample testing may involve the use of modern battery operated moisture meters (described earlier) or a sample weighing method where moisture con- tent can be calculated by a boards loss in weight. Figure 1.41 shows how timber is piled and provision is made in a stack for the easy removal of board samples. Figure 1.42 shows a sample board being removed from the stack – notice also the control panel outside the kiln with its relative humidity recorder. The weighing method involves cutting out oven samples from each sample board as shown in figure 1.43 then finding its moisture content by the oven dry method previously described (section 1.7.1(a)). The kiln sample is then weighed to obtain its wet weight; its dry weight can then be calculated by using a simple calcu- lation. Future checks are then made by re- weighing the kiln sample, and cross-referencing the results with a drying table chart. However, by using modern control equipment that is fully automatic the moisture content of timber within the kiln can be continually moni- tored, enabling the equilibrium moisture content (EMC) to be controlled according to the wood species and sectional size of the timber. 28 Timber Sticks vertically in-line Boards edge to edge Sticks cut-away Double stick Fig 1.41 Two examples of how provision can be made for easy removal of kiln samples Fig 1.42 Inspection and removal of a kiln sample (permission Wells Ltd.) Sample board (kiln sample) 250mm Oven sample 15mm Fig 1.43 Cutting an oven sample to determine the moisture content of the sample board 1.7.6 Compartment kilns (dryers) These are sealable drying chambers (compart- ments) which house batches of timber, loaded on trolleys, until their drying schedule is complete. Figure 1.44 shows how these kilns can be arranged – separately with single, double, or triple tracks, or joined together in a row (battery). Kilns may be sited outside, like that shown in figure 1.45 and figure 1.46, or undercover like the battery of dryers shown in figure 1.47, which receive heat from a central boiler plant. Figure 1.48 shows how timber piles are stacked in a double-track kiln with a central unit containing the large fan, heaters, humidifiers, ventilators, and controls. Figure 1.49 has a simi- lar unit to one side to accommodate three tracks. Figure 1.50 shows a compartment dryer with a overhead circulation unit. 1.7.7 Progressive kilns (continuous dryers) Green timber enters the kiln at one end, and after a period of time which can be as short as three to five days, depending on the species and the cross-section – emerges from the exit at the opposite end in a much drier state. The whole process enables timber to be dried by continu- ous means. Figure 1.51 shows how batches of timber are lined up on trolleys on tracks outside the dryer, Drying timber 29 Single track Double track Triple track Track Track Battery of single-track dryers 1 2 3 4 5 6 Ventilation Track to sealable chamber Heating pipes and humidifier Fan ciculates air Fig 1.44 Types of compartment dryers (for the sake of clarity some doors are not shown) Fig 1.45 External sited compartment dryers (with kind permission of ‘Kiln Services Ltd’) Fig 1.46 Externally sited battery of compartment dryers – one being loaded with timber (with kind promise of ‘Wells Ltd’) ready to follow those already inside. On entry, each batch will go through a series of stationary drying stages, which start cool and humid but end with the last stage being warm and dry. When a batch leaves the dryer, a new batch will enter from the other end to take its place. For this method of drying to be cost effective it requires a continuous run of timber of similar species with common drying characteristics and sectional size like those you might find in large mills specialising in drying softwoods. 1.7.8 Drying defects Successful drying depends on how drying preparations are made and on how the whole operation is carried out. Green timber is usually in a pliable state – after drying it stiffens and sets. For example, a green twig will bend easily but, if held in that position until dry, it will set and remain partially bent. Therefore, if green timber is allowed to become distorted, either by incorrect piling (fig 30 Timber Vents Trolley TrackFan and drying unit Fig 1.48 Cross section through a ‘Wells’ double track high-stacking prefabricated timber dryer Vents Trolley Track Fan and drying unit Fig 1.49 Cross section through a ‘Wells’ triple track high-stacking prefabricated timber dryer Fig 1.50 Cutaway view of a double stack rail entry kiln (kindly supplied by ‘Kiln Services Ltd’) Fig 1.47 Undercover battery of compartment dryers (with kind promise of ‘Wells Ltd’) 1.39) or due to unbalanced shrinkage during its drying, then permanent degrading could result. By using table 1.7, and the accompanying illustrations featured in figures 1.52 to 1.62, you should be able to recognise each of the listed defects. These defects have been grouped as: ● Stains ● Distortions ● Checking & splitting ● Case-hardening it can be seen that most of these degrading defects can be attributed to both the unevenness and the speed at which moisture is removed from the wood. It is important to remember at this stage how moisture is lost from the wood as it dries. As shown in figure 1.63 on drying, the outer surface of the wood dries first, and as the moisture is lost through evaporation, all things being equal it is replaced with that contained within the wood. If this flow is restricted due to any imbalance, internal stresses within the wood will be created resulting in many of the defects listed. 1.8 Grading timber Like other natural materials with inherent varia- tions, timber is required to meet certain stan- dards so that it can be classified suitable for a particular end use. Two of the main issues to be considered here are the timbers appearance and its strength qualities. For the purpose of this chapter we shall call the grading rules set down for appearance as ‘commercial grading’, and
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